Process of making cement and other products.



S. PEAGOOK.

PROCESS OF MAKING CEMENT AND OTHER PRODUCTS.

APPLICATION FILED JUNE 17,1909

939,078. Patented Nov. 2, 1909.

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UNITED STATES PATENT OFFICE.

SAMUEL PEACOCK, OF CHICAGO, ILLINOIS, ASSIGNOB TO AMERICAN CYANAMID COM- PANY, OF NEW YORK, N. Y., A. CORPORATION OF MAINE.

PROCESS OF MAKING CEMENT AND OTHER PRODUCTS.

Specification of Letters Patent.

Patented Nov. 2, 1909.

Application filed June 17, 1900. Serial No. 508,192.

To all whom it may concern.

Be it known that I, SAMUEL PEACOCK, a citizen of the United States, residing at Chicago, in the county of Cook and Stateof Illinois, have invented certain new and useful Improvements in Processes for Making Cement and other Products; and I do hereby declare the followin to be a full, clear, and exact description 0? the invention, such as will enable others skilled in the art to which it appertains to make and use the same.

This invention relates to a process of making. Portland cement and the pentoxid 'of phosphorus, P 0 from phosphate rock, and has for its object the making of these two products in a single, simple, and comparatively less expensive manner, than heretofore.

To these ends the invention consists in the novel steps and combinations of steps constituting my process, fully hereinafter disclosed, and particularly pointed out in the claims.

Referring to the accompanying drawings forming a part of this specification, in which the figure 1s a diagrammatic sectional view of a well known type of rotary furnace 1 represents. suitable supports, 2 stationa ends provided with an orifice 3 for the a mission of fuel, and a passage 4 for the exit of the gases 5 a rotary barrel part adapted to receive the mixture, and 6 suitable mechanism for rotating said barrel.

7 represents a' receiving hopper, 8 a screw conveyor, and 9 a delivery s out for the mixture, while 10 designates a elivery from the lower end of the furnace, under which suitable rece tacles 12 may be placed.

As is we known, the essential constituents of Portland cement may be represented as composed substantially as follows 2CaO-}-I*e,() and it is equally well known that the proportions of the silica to the alumina and to the ferric oxid should conform to the formula:

i E ,0 +Fe,0, 2 4 That is to say, the weight of the silica di- Low Grade Phosphate Rock.

B. P. L--- 65-261). ct. CaCo 10.31 P 0 29. 80 CaO 41-. 20 AI Q 5.20 gn cc 1 2 CO 4.50 H O 2.40

The following recognized average analysis of Portland cement may also be taken as a basis for calculation SiO 220p. ct. CaO 67.0 A1 0 6.0 Fe,() 2.0

g0 so Ratio of SiO, to A1,,O,+Fe,0',=2.75.

In this latter analysis the almmina oxid, A1 0 added to the ferric oxid, Fe,O,, amounts to 8%, while the silica, SiO,, amounts to 22%. In other words, the ratio of SiO to Al,O,|-Fe,0,, is about 2.75. The phosphate, however, of the first analysis, gives SiO as 14%; and Al O +Fe 05 as 8.10%, or a ratio of only about 1.70; and it is evident, that if the Portland cement is to be made from such ingredients, it is necessary that this ratio be raised to about 2.70. In order to do this I add to every one hun dred pounds of hosphate rock about 8.3 pounds of SiO,, w en the total acid oxide in the mixture become for each one hundred pounds of phosphate rock, about as follows z- Silica, SiO' 22. 3' lbs.

Alummum oxid, A1 0,--- 5. 2, Ferric oxid',.Fe,O 2. 9

Therefore, in order to satis the. required reactions in making Port cement, these acid oxids require calcium Add, 0110, about as follows 22. 30 lbs. SiO. require 62.20 lbs. CaO 5.20 A1 0 5370 u a. 2. 1O v F9 0 2 10 u a u Total CaO required 70. 00 lbs.

But, from the first analysis above, it is seen that 100 lbs. of the phosphate contains only 41.20 lbs. of calcium oxid, C210; and, therefore, I add again to the mixture 28.80 lbs. CaO or 51.60 lbs. pure carbonate of lime in order to get the pounds of ()aO, necessary to satisfy the acid oxids present. When this is done I have a furnace mixture properly proportioned for, producing Portland cement.

The reactions which occur in carryingout this process are as follows:

In other words, in carrying out my invention, I may take 100 lbs. of, say, low grade phosphate rock, of a proximately the analysis above, and, I ad thereto about 8.30 lbs. of silica, and about 51.60 lbs. of carbonate of lime, making a furnace mixture of 159.90 lbs. These ingredients are pre ared in the ordinary way for making Port and cement, passed through and heated in a suitable Portland cement furnace, as that shown, to about 1400 (3., during which treatment the following substances pass off as gases through the openlng 4:

Pentoxid of phos horus, P 0 29. 8 lbs. Carbon dioxid, 0 from phosphate rock 4.5 Carbon dioxid, from limestone 22. 8 Water, H O 2.4

Total 59.5

silica 31 lime carbonate 195 The 379ylbs. of hosphate rock, however, will contain 113*1 s, of hosphorous pentoxid, P 0 and, if wea ow a loss of 5% in the process of manufacture, the actual rebe 107 lbs. Accordingly, if my process of making Portland cement and recovering P 0 is compared with the older process, it

will be found that I get a product of 107 lbs. of free phosphorous pentoxid, P 0 for each barrel of cement; and I also get a barrel of Portland cement at a cost of about the same as under the old process of makin cement, omitting, of course, the cost 0 the phosphate rock.

It should be observed that my process does not require any carbon in the mixture, nor any reduction of the P 0 at any stage of the process. In fact, it has been heretofore proposed to mold a mixture of phosphate and silica into balls and to treatthe-same with carbon in a cupola furnace. But, such a process cannot produce phosphorous pentoxid, P 0 becausethe carbon present reduces the same; nor could such a procedure produce Portland cement and P 0 should the carbon be omitted, because the production of a basic silicate is not possible without a very intimate intermixture of the lime and silicate. If the balls are present in the furnace, it is well known that the physical relations of the molecules are such that this intimate intermixture is not present and that, therefore, such basic silicate cannot be formed.

Of course, it is understood that the above analyses are merely illustrative, and the proportions of the various ingredients will vary according to the quality of the hos hate rock that may be actually se ecte in practice.

WV hat I claim is:

1. The process of making free pentoxid of phosphorus, P 0 and Portland cement in a single operation from phosphate rock, which consists in providing a rock mixture in which the ratio of the total silica SiO to the total alumina and ferric oxid is greater than 2 and less than 4; and in suitably treating said mixture to form Portland cement and to separate and'recover the P 0 substantially as described.

2. The process of making free pentoxid of phosphorus, P 0 and Portland cement in a single operation from a phosphate rock mixture which consists in causing suflicient silica, SiO to be present in said rock to seems in the mixture greater than .2 and less than i in adding sutlicient ".alciuin oxicl, (lath to combine with the acid oxide present; Hilll in suitably treating the mixture thus obtained to form Portland cementand to separate and recover the free P O rsuhstaln tially as described.

4. The process of making free pentoxid of phosphorus, P 0 and Portland cement in a single operation from phosphate rock which consists in adding to each one hundred pounds of phosphate rock substan tially 8.3 poumls of silica Sit) and substantially 51.60 lhs.- of carbonate of lime, suitably preparing and treating this mixture to form Portland cement and to drive ott' the P 0 and in suitably recovering said P 0 substantially as described.

5. The process of making Portland cement from a phosphate rock mixture, which consists in causing suliicient silica to be present in Silltl mixture to make the ratio of the total silica to the total alumina plus the terric oxid in the mixture, greater than 2 and less than at; causing suflicient calcium oxicl, (lat) to be present to chemically combine with the total acicl oxids present in the mixture; and in suitably treating the mixture to cause the said ingredients to chemically react; substantially as described.

In testimony whereof, I allix my signature, in presence of two Witnesses.

SAMUEL PEACOCK Witnesses T. A. W rrnnasroon, ROLAND O. BOOTH. 

